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EP2982470A1 - Method for producing a rotor of a charging apparatus - Google Patents

Method for producing a rotor of a charging apparatus Download PDF

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Publication number
EP2982470A1
EP2982470A1 EP15175069.2A EP15175069A EP2982470A1 EP 2982470 A1 EP2982470 A1 EP 2982470A1 EP 15175069 A EP15175069 A EP 15175069A EP 2982470 A1 EP2982470 A1 EP 2982470A1
Authority
EP
European Patent Office
Prior art keywords
rotor
radial bearing
radial
bearing surfaces
bearing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP15175069.2A
Other languages
German (de)
French (fr)
Other versions
EP2982470B1 (en
Inventor
Michal Klusácek
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BMTS Technology GmbH and Co KG
Original Assignee
Bosch Mahle Turbo Systems GmbH and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bosch Mahle Turbo Systems GmbH and Co KG filed Critical Bosch Mahle Turbo Systems GmbH and Co KG
Publication of EP2982470A1 publication Critical patent/EP2982470A1/en
Application granted granted Critical
Publication of EP2982470B1 publication Critical patent/EP2982470B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
    • B23P13/02—Making metal objects by operations essentially involving machining but not covered by a single other subclass in which only the machining operations are important
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
    • F01D11/02—Preventing or minimising internal leakage of working-fluid, e.g. between stages by non-contact sealings, e.g. of labyrinth type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/006—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine wheels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/16—Arrangement of bearings; Supporting or mounting bearings in casings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/28—Supporting or mounting arrangements, e.g. for turbine casing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F01D5/027—Arrangements for balancing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/02—Blade-carrying members, e.g. rotors
    • F01D5/06—Rotors for more than one axial stage, e.g. of drum or multiple disc type; Details thereof, e.g. shafts, shaft connections
    • F01D5/063—Welded rotors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B37/00—Engines characterised by provision of pumps driven at least for part of the time by exhaust
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/40—Application in turbochargers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/60—Assembly methods
    • F05D2230/61—Assembly methods using limited numbers of standard modules which can be adapted by machining
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/24—Rotors for turbines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/50—Bearings
    • F05D2240/54—Radial bearings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/55—Seals
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to a method for producing a rotor of a charging device, in particular an exhaust gas turbocharger, with a compressor wheel and a turbine wheel according to the preamble of claim 1.
  • the invention also relates to a rotor produced by this method and a charging device with such a rotor.
  • Rotors for exhaust gas turbochargers or for charging devices in general are usually composed of several parts, for example a turbine wheel, a shaft and a compressor wheel.
  • the individual parts are manufactured separately with rotationally symmetrical end contours. After fabrication, the pre-balanced individual parts, such as the compressor wheel and the turbine wheel, are mounted to the rotor. After final assembly, the rotor is balanced again.
  • a disadvantage of the known manufacturing method is that in this case the individual rotor parts must be balanced separately and, despite the fact that there are no exactly rotationally symmetrical surfaces on the rotor after assembly.
  • the present invention therefore deals with the problem of providing a method of the generic type of an improved or at least alternative embodiment, by means of which a comparatively simple and yet highly accurate production of a balanced rotor with rotationally symmetrical surfaces is possible.
  • the present invention is based on the general idea of producing individual parts of a rotor, for example a turbine wheel and a compressor wheel or bearing sections, with radial oversize, then assembling them into a rotor and processing it in a completely assembled state, for example by turning or grinding. until it is rotationally symmetric.
  • the advantages of the method according to the invention are in particular that the individual rotor parts, that is, for example, the compressor or the turbine wheel or the bearing sections, do not have to be balanced separately and also all important surfaces of a voltage, that is in a clamped operation made which ensures maximum concentricity while keeping costs to a minimum.
  • the turbine wheel is connected to the compressor wheel via a labyrinth seal, wherein a bearing section for supporting the rotor in a bearing housing of the charging device is provided on the longitudinal end side.
  • the rotor assembled from bearing sections, turbine wheel, labyrinth seal and compressor wheel is machined, in particular rotated or ground, for example in a lathe or centerless, until it is rotationally symmetrical.
  • At least two components of the rotor for example, the compressor wheel, the turbine wheel, a bearing section or the labyrinth seal welded together, soldered, screwed or glued.
  • the compressor wheel for example, the compressor wheel, the turbine wheel, a bearing section or the labyrinth seal welded together, soldered, screwed or glued.
  • the axial end faces of the bearing sections are machined by means of EDM or by grinding.
  • a turning of the rotor can be carried out in particular on the axial end faces of the bearing sections only close to a center hole, since the rotor clamped in the region of the center hole in a spindle of the lathe and thereby can not be edited there.
  • the non-machinable region of the centering can thus not be processed "out of tension", and is therefore eroded away or reground after removal of the rotor from the lathe.
  • an axial air bearing is etched or eroded into the axial end faces.
  • Such an air bearing offers a particularly low-friction and at the same time wear-free storage, wherein the air ducts required for this purpose can be produced cost-effectively, but nevertheless with high precision by means of etching or erosion processes or even a laser process.
  • FIG. 1 is a inventively produced rotor 1 of a loader not shown otherwise, with a compressor 2, a labyrinth seal 3 and a turbine 4.
  • Each longitudinal end of the compressor 2 and in the turbine 4 is also a bearing portion with radial bearing surfaces 5 and 5 ' arranged.
  • the individual components of the rotor 1, that is, for example, the turbine wheel 2, the labyrinth seal 3, the compressor 4 and the bearing sections can be non-positively, cohesively or positively connected with each other, in particular glued together, screwed, welded or soldered.
  • outer radial bearing surfaces 5, 5 ' which are preferably designed as radial air bearings and take over the radial bearing of the rotor 1
  • an axial air bearing to be arranged in the region of the bearing sections, so that the entire rotor 1 is preferably air-stored both in the radial direction and in the axial direction.
  • the rotor 1 is now produced in that at least the radial bearing surfaces 5, 5 'manufactured with radial oversize and then connected to the compressor 2 and the turbine wheel 4 to the rotor 1 with each other.
  • the compressor wheel 2 and the turbine wheel 4 and the labyrinth seal 3 are also made with radial oversize.
  • the labyrinth seal 3 it is also possible to provide a shaft which connects the compressor wheel 2 to the turbine wheel 4.
  • the fully assembled rotor 1 is clamped in a lathe and processed, in particular rotated or ground until it is rotationally symmetrical.
  • lathe is intended to stand as a placeholder for a processing machine, which of course not only allows a rotation, but also a grinding or otherwise editing the surfaces of the rotor 1 in terms of optimized rotational symmetry.
  • the post-processing in "a voltage" to achieve optimum concentricity of all surfaces of the individual components of the rotor 1, which reduces the imbalance and simplifies the assembly of the rotor 1 in the charging device.
  • the areas around the centering holes 7 can not be processed in the lathe, so that these areas are ground away after erasing the rotor 1 or eroded away.
  • the leading edges of the compressor wheel blades and the trailing edges of the turbine blades are also not machined in tension.
  • the bearing sections serve the radial bearing of the rotor 1 in a bearing housing of the charging device, wherein after machining the rotor 1 in the lathe, the axial end faces 8, 8 'of an axial bearing 9 (see FIG. 2 ) be processed by laser structuring.
  • the individual spirally arranged grooves 10 forming the axial air bearing 9 to be produced otherwise, for example by means of etching or erosion or by means of a metal-cutting process.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Supercharger (AREA)

Abstract

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Rotors (1) einer Ladeeinrichtung, insbesondere eines Abgasturboladers, mit zumindest einem Verdichterrad (2) und einem Turbinenrad (4), wobei längsendseitig jeweils noch ein Lagerabschnitt mit einer Radiallagerfläche (5, 5') zum Lagern des Rotors (1) in einem Lagergehäuse vorgesehen ist. Erfindungswesentlich ist dabei, - dass zumindest die Radiallagerflächen (5, 5') mit radialem Übermaß gefertigt werden, - dass das Verdichterrad (2) und das Turbinenrad (4) und die Lagerabschnitte zum Rotor (1) zusammengebaut werden, - dass zumindest die Radiallagerflächen (5, 5') des fertig zusammengebauten Rotors (1) anschließend bearbeitet, insbesondere gedreht oder geschliffen wird, bis die Radiallagerflächen (5, 5') rotationssymmetrisch sind. Hierdurch kann ein rotationssymmetrischer Rotor (1) kostengünstig und einfach gefertigt werden.The present invention relates to a method for producing a rotor (1) of a charging device, in particular an exhaust gas turbocharger, with at least one compressor wheel (2) and a turbine wheel (4), wherein each longitudinal end still a bearing portion with a radial bearing surface (5, 5 ') Storage of the rotor (1) is provided in a bearing housing. Essential to the invention is - That at least the radial bearing surfaces (5, 5 ') are manufactured with radial oversize, - That the compressor wheel (2) and the turbine wheel (4) and the bearing sections to the rotor (1) are assembled, - That at least the radial bearing surfaces (5, 5 ') of the finished assembled rotor (1) subsequently processed, in particular rotated or ground until the radial bearing surfaces (5, 5') are rotationally symmetrical. In this way, a rotationally symmetrical rotor (1) can be manufactured inexpensively and easily.

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Rotors einer Ladeeinrichtung, insbesondere eines Abgasturboladers, mit einem Verdichterrad und einem Turbinenrad gemäß dem Oberbegriff des Anspruchs 1. Die Erfindung betrifft außerdem einen nach diesem Verfahren hergestellten Rotor sowie eine Ladeeinrichtung mit einem derartigen Rotor.The present invention relates to a method for producing a rotor of a charging device, in particular an exhaust gas turbocharger, with a compressor wheel and a turbine wheel according to the preamble of claim 1. The invention also relates to a rotor produced by this method and a charging device with such a rotor.

Rotoren für Abgasturbolader bzw. für Ladeeinrichtungen allgemein sind üblicherweise aus mehreren Teilen zusammengesetzt, beispielsweise einem Turbinenrad, einer Welle und einem Verdichterrad. Die einzelnen Teile sind dabei separat mit rotationssymmetrischen Endkonturen gefertigt. Nach der Fertigung werden die vorgewuchteten einzelnen Teile, beispielsweise das Verdichterrad und das Turbinenrad, zu dem Rotor montiert. Nach der Endmontage wird der Rotor nochmals gewuchtet.Rotors for exhaust gas turbochargers or for charging devices in general are usually composed of several parts, for example a turbine wheel, a shaft and a compressor wheel. The individual parts are manufactured separately with rotationally symmetrical end contours. After fabrication, the pre-balanced individual parts, such as the compressor wheel and the turbine wheel, are mounted to the rotor. After final assembly, the rotor is balanced again.

Nachteilig bei dem bekannten Fertigungsverfahren ist jedoch, dass hierbei die einzelnen Rotorteile separat gewuchtet werden müssen und nach der Montage trotz allem keine exakt rotationssymmetrischen Oberflächen am Rotor vorliegen.A disadvantage of the known manufacturing method, however, is that in this case the individual rotor parts must be balanced separately and, despite the fact that there are no exactly rotationally symmetrical surfaces on the rotor after assembly.

Die vorliegende Erfindung beschäftigt sich daher mit dem Problem, für ein Verfahren der gattungsgemäßen Art eine verbesserte oder zumindest alternative Ausführungsform anzugeben, mittels welcher eine vergleichsweise einfache und dennoch hochpräzise Herstellung eines gewuchteten Rotors mit rotationssymmetrischen Oberflächen möglich ist.The present invention therefore deals with the problem of providing a method of the generic type of an improved or at least alternative embodiment, by means of which a comparatively simple and yet highly accurate production of a balanced rotor with rotationally symmetrical surfaces is possible.

Dieses Problem wird erfindungsgemäß durch den Gegenstand des unabhängigen Anspruchs 1 gelöst. Vorteilhafte Ausführungsformen sind Gegenstand der abhängigen Ansprüche.This problem is solved according to the invention by the subject matter of independent claim 1. Advantageous embodiments are the subject of the dependent claims.

Die vorliegende Erfindung beruht auf dem allgemeinen Gedanken, einzelne Teile eines Rotors, beispielsweise ein Turbinenrad und ein Verdichterrad oder Lagerabschnitte, mit radialem Übermaß zu fertigen, anschließend zu einem Rotor zusammenzubauen und diesen in fertig montiertem Zustand zu bearbeiten, beispielsweise zu drehen oder zu schleifen, bis er rotationssymmetrisch ist. Die Vorteile bei dem erfindungsgemäßen Verfahren liegen dabei insbesondere darin, dass die einzelnen Rotorteile, das heißt beispielsweise das Verdichterrad oder das Turbinenrad oder die Lagerabschnitte, nicht separat gewuchtet werden müssen und zudem alle wichtigen Oberflächen aus einer Spannung, das heißt in einem eingespannten Arbeitsschritt, gefertigt werden, wodurch eine maximale Konzentrizität bei gleichzeitig minimalen Kosten gewährleistet werden kann.The present invention is based on the general idea of producing individual parts of a rotor, for example a turbine wheel and a compressor wheel or bearing sections, with radial oversize, then assembling them into a rotor and processing it in a completely assembled state, for example by turning or grinding. until it is rotationally symmetric. The advantages of the method according to the invention are in particular that the individual rotor parts, that is, for example, the compressor or the turbine wheel or the bearing sections, do not have to be balanced separately and also all important surfaces of a voltage, that is in a clamped operation made which ensures maximum concentricity while keeping costs to a minimum.

Bei einer vorteilhaften Weiterbildung des erfindungsgemäßen Verfahrens wird das Turbinenrad über eine Labyrinthdichtung mit dem Verdichterrad verbunden, wobei längsendseitig jeweils noch ein Lagerabschnitt zum Lagern des Rotors in einem Lagergehäuse der Ladeeinrichtung vorgesehen wird. Anschließend wird der aus Lagerabschnitten, Turbinenrad, Labyrinthdichtung und Verdichterrad fertig zusammengebaute Rotor bearbeitet, insbesondere gedreht oder geschliffen, beispielsweise in einer Drehbank oder spitzenlos, bis er rotationssymmetrisch ist. Hierdurch ist nicht nur die rotationssymmetrische Bearbeitung des Turbinenrades und des Verdichterrades möglich, sondern zugleich auch der Labyrinthdichtung bzw. der beiden Lagerabschnitte.In an advantageous development of the method according to the invention, the turbine wheel is connected to the compressor wheel via a labyrinth seal, wherein a bearing section for supporting the rotor in a bearing housing of the charging device is provided on the longitudinal end side. Subsequently, the rotor assembled from bearing sections, turbine wheel, labyrinth seal and compressor wheel is machined, in particular rotated or ground, for example in a lathe or centerless, until it is rotationally symmetrical. As a result, not only the rotationally symmetric machining of the turbine wheel and the compressor wheel is possible, but at the same time also the labyrinth seal or the two bearing sections.

Zweckmäßig sind zumindest zwei Bauteile des Rotors, beispielsweise das Verdichterrad, das Turbinenrad, ein Lagerabschnitt oder die Labyrinthdichtung miteinander verschweißt, verlötet, verschraubt oder verklebt. Bereits diese nicht abschließende Aufzählung lässt erahnen, welch mannigfaltige Möglichkeiten der Verbindung der einzelnen Teile des Rotors möglich sind, so dass diese beispielsweise kraftschlüssig, formschlüssig und/oder stoffschlüssig miteinander verbunden werden können.Suitably, at least two components of the rotor, for example, the compressor wheel, the turbine wheel, a bearing section or the labyrinth seal welded together, soldered, screwed or glued. Already this non-exhaustive list lets us guess what manifold possibilities of the connection of the individual parts of the rotor are possible, so that this example non-positively, positively and / or materially connected to each other.

Bei einer weiteren vorteilhaften Ausführungsform der erfindungsgemäßen Lösung werden die axialen Stirnflächen der Lagerabschnitte mittels Erodierverfahren oder mittels Schleifverfahren bearbeitet. Eine Drehbearbeitung des Rotors kann dabei insbesondere auf den axialen Stirnseiten der Lagerabschnitte nur bis nahe an eine Zentrierbohrung durchgeführt werden, da der Rotor im Bereich der Zentrierbohrung in eine Spindel der Drehbank eingespannt und dadurch dort nicht bearbeitet werden kann. Der nicht bearbeitbare Bereich der Zentrierung kann somit nicht "aus einer Spannung" bearbeitet werden, und wird deshalb nach Entfernen des Rotors aus der Drehbank wegerodiert bzw. nachgeschliffen. Somit lassen sich mit dem erfindungsgemäßen Verfahren bis auf die Zentrierbohrungen alle Oberflächenbereiche des Rotors bearbeiten, wodurch dieser hinsichtlich seiner Rotationssymmetrie optimal hergestellt werden kann, was sich selbstverständlich auch positiv auf eine unter Umständen vorhandene Unwucht auswirkt. Auch die Montage des Rotors in die Ladeeinrichtung wird hierdurch vereinfacht.In a further advantageous embodiment of the solution according to the invention, the axial end faces of the bearing sections are machined by means of EDM or by grinding. A turning of the rotor can be carried out in particular on the axial end faces of the bearing sections only close to a center hole, since the rotor clamped in the region of the center hole in a spindle of the lathe and thereby can not be edited there. The non-machinable region of the centering can thus not be processed "out of tension", and is therefore eroded away or reground after removal of the rotor from the lathe. Thus, with the method according to the invention, all surface areas of the rotor can be processed, except for the centering bores, so that this can be optimally manufactured with regard to its rotational symmetry, which of course also has a positive effect on an imbalance that may exist. The assembly of the rotor in the charging device is thereby simplified.

Bei einer weiteren vorteilhaften Ausführungsform der erfindungsgemäßen Lösung wird in die axialen Stirnflächen ein Axialluftlager geätzt oder erodiert. Ein derartiges Luftlager bietet eine besonders reibungsarme und zugleich verschleißfreie Lagerung, wobei die hierfür erforderlichen Luftleitrillen kostengünstig, aber dennoch hochpräzise mittels Ätz- oder Erodierverfahren oder aber auch eines Laserverfahrens hergestellt werden können.In a further advantageous embodiment of the solution according to the invention, an axial air bearing is etched or eroded into the axial end faces. Such an air bearing offers a particularly low-friction and at the same time wear-free storage, wherein the air ducts required for this purpose can be produced cost-effectively, but nevertheless with high precision by means of etching or erosion processes or even a laser process.

Weitere wichtige Merkmale und Vorteile der Erfindung ergeben sich aus den Unteransprüchen, aus den Zeichnungen und aus der zugehörigen Figurenbeschreibung anhand der Zeichnungen.Other important features and advantages of the invention will become apparent from the dependent claims, from the drawings and from the associated figure description with reference to the drawings.

Es versteht sich, dass die vorstehend genannten und die nachstehend noch zu erläuternden Merkmale nicht nur in der jeweils angegebenen Kombination, sondern auch in anderen Kombinationen oder in Alleinstellung verwendbar sind, ohne den Rahmen der vorliegenden Erfindung zu verlassen.It is understood that the features mentioned above and those yet to be explained below can be used not only in the particular combination given, but also in other combinations or in isolation, without departing from the scope of the present invention.

Bevorzugte Ausführungsbeispiele der Erfindung sind in den Zeichnungen dargestellt und werden in der nachfolgenden Beschreibung näher erläutert, wobei sich gleiche Bezugszeichen auf gleiche oder ähnliche oder funktional gleiche Bauteile beziehen.Preferred embodiments of the invention are illustrated in the drawings and will be described in more detail in the following description, wherein like reference numerals refer to the same or similar or functionally identical components.

Dabei zeigen, jeweils schematisch,

Fig. 1
einen erfindungsgemäßen Rotor in einer Seitenansicht,
Fig. 2
eine Stirnansicht auf einen Lagerabschnitt des Rotors mit einem Axialluftlager.
Show, in each case schematically,
Fig. 1
a rotor according to the invention in a side view,
Fig. 2
an end view of a bearing portion of the rotor with a Axialluftlager.

Entsprechend der Figur 1 ist ein erfindungsgemäß hergestellter Rotor 1 einer im Übrigen nicht gezeigten Ladeeinrichtung dargestellt, mit einem Verdichterrad 2, einer Labyrinthdichtung 3 sowie einem Turbinenrad 4. Jeweils längsendseitig am Verdichterrad 2 bzw. im Turbinenrad 4 ist darüber hinaus noch ein Lagerabschnitt mit Radiallageroberflächen 5 bzw. 5' angeordnet. Die einzelnen Bauteile des Rotors 1, das heißt beispielsweise das Turbinenrad 2, die Labyrinthdichtung 3, das Verdichterrad 4 sowie die Lagerabschnitte können dabei kraftschlüssig, stoffschlüssig oder formschlüssig miteinander verbunden sein, insbesondere miteinander verklebt, verschraubt, verschweißt oder verlötet.According to the FIG. 1 is a inventively produced rotor 1 of a loader not shown otherwise, with a compressor 2, a labyrinth seal 3 and a turbine 4. Each longitudinal end of the compressor 2 and in the turbine 4 is also a bearing portion with radial bearing surfaces 5 and 5 ' arranged. The individual components of the rotor 1, that is, for example, the turbine wheel 2, the labyrinth seal 3, the compressor 4 and the bearing sections can be non-positively, cohesively or positively connected with each other, in particular glued together, screwed, welded or soldered.

Neben den außenliegenden Radiallagerflächen 5, 5', welche vorzugsweise als Radialluftlager ausgebildet sind und die Radiallagerung des Rotors 1 übernehmen, kann im Bereich der Lagerabschnitte auch ein Axialluftlager angeordnet sein, so dass der gesamte Rotor 1 vorzugsweise sowohl in Radialrichtung als auch in Axialrichtung luftgelagert wird.In addition to the outer radial bearing surfaces 5, 5 ', which are preferably designed as radial air bearings and take over the radial bearing of the rotor 1, it is also possible for an axial air bearing to be arranged in the region of the bearing sections, so that the entire rotor 1 is preferably air-stored both in the radial direction and in the axial direction.

Erfindungsgemäß wird nun der Rotor 1 dadurch hergestellt, dass zumindest die Radiallagerflächen 5, 5' mit radialem Übermaß gefertigt und anschließend mit dem Verdichterrad 2 und mit dem Turbinenrad 4 zu dem Rotor 1 miteinander verbunden werden. Vorzugsweise sind das Verdichterrad 2 und das Turbinenrad 4 und die Labyrinthdichtung 3 ebenfalls mit radialem Übermaß gefertigt. Dabei kann selbstverständlich anstelle der Labyrinthdichtung 3 auch eine Welle vorgesehen sein, die das Verdichterrad 2 mit dem Turbinenrad 4 verbindet. Anschließend wird der fertig zusammengebaute Rotor 1 in eine Drehbank eingespannt und bearbeitet, insbesondere gedreht oder geschliffen, bis er rotationssymmetrisch ist. Der Begriff "Drehbank" soll dabei als Platzhalter für eine Bearbeitungsmaschine stehen, die selbstverständlich nicht nur ein Drehen, sondern auch ein Schleifen oder anderweitiges Bearbeiten der Oberflächen des Rotors 1 im Hinblick auf eine optimierte Rotationssymmetrie ermöglicht.According to the invention, the rotor 1 is now produced in that at least the radial bearing surfaces 5, 5 'manufactured with radial oversize and then connected to the compressor 2 and the turbine wheel 4 to the rotor 1 with each other. Preferably, the compressor wheel 2 and the turbine wheel 4 and the labyrinth seal 3 are also made with radial oversize. Of course, instead of the labyrinth seal 3, it is also possible to provide a shaft which connects the compressor wheel 2 to the turbine wheel 4. Subsequently, the fully assembled rotor 1 is clamped in a lathe and processed, in particular rotated or ground until it is rotationally symmetrical. The term "lathe" is intended to stand as a placeholder for a processing machine, which of course not only allows a rotation, but also a grinding or otherwise editing the surfaces of the rotor 1 in terms of optimized rotational symmetry.

Insbesondere kann anstelle des Einspannens in eine Drehbank auch ein spitzenloses Bearbeiten erfolgen. Hierbei wird das Werkstück nicht zwischen Spindelstock und Reitstock eingespannt, sondern zwischen Schleif- und Regelscheibe geführt und dabei von unten mittels einer Schiene gehalten. Man unterscheidet Einstechschleifen und Durchlaufschleifen. Bei letzterer Methode können sehr hohe Durchsätze erzielt werden. Eine spezielle Version sind spitzenlose Schuhschleifmaschinen, bei denen Auflageschiene und Regelscheibe durch Stahlschuhe ersetzt sind. Damit lassen sich spezielle Geometrien in einem Arbeitsgang schleifen.In particular, instead of clamping in a lathe also a centerless editing done. Here, the workpiece is not clamped between the headstock and tailstock, but passed between grinding and regulating wheel and held it from below by means of a rail. One distinguishes plunge grinding and continuous grinding. In the latter method very high throughputs can be achieved. A special version are centerless shoe grinding machines, where the support rail and regulating wheel are replaced by steel shoes. This allows special geometries to be ground in one operation.

Bei der gemäß der Figur 1 gezeigten Darstellung des Rotors 1 werden selbstverständlich sämtliche Bauteile des Rotors 1, das heißt also der Lagerabschnitt mit der Radiallagerfläche 5, das Verdichterrad 2, die Labyrinthdichtung 3, das Turbinenrad 4 sowie der Lagerabschnitt mit Radiallagerfläche 5' zuerst miteinander zu dem Rotor 1 verbunden und dieser anschließend in fertig montiertem Zustand, insbesondere in die Drehbank eingespannt und dort, nachbearbeitet. Mit der Nachbearbeitung in "einer Spannung" erreicht man eine optimale Konzentrizität von allen Oberflächen der einzelnen Bauteile des Rotors 1, was die Unwucht reduziert und die Montage des Rotors 1 in der Ladeeinrichtung vereinfacht. Alternativ kann anstelle des Einspannens in eine Drehbank auch ein spitzenloses Bearbeiten erfolgen, wobei das das Werkstück nicht zwischen Spindelstock und Reitstock eingespannt, sondern zwischen Schleif- und Regelscheibe geführt und von unten mittels einer Schiene gehalten wird. Die möglichen Oberflächen des Rotors 1, die bei dem erfindungsgemäßen Verfahren nachbearbeitet werden, sind dabei in Figur 1 mit der Linie 6 bezeichnet. Es ist somit möglich, den nahezu gesamten Rotor 1 mit Ausnahme eines kleinen Bereichs im Bereich der Zentrierbohrungen 7 nachzuarbeiten und dabei hinsichtlich der Rotationssymmetrie zu optimieren. Es wäre aber auch denkbar, ausschließlich die außenliegenden Radiallagerflächen 5, 5' des Rotors 1 in einer Spannung zu bearbeiten.In accordance with the FIG. 1 shown representation of the rotor 1 are of course all components of the rotor 1, that is, the bearing portion with the radial bearing surface 5, the compressor 2, the labyrinth seal 3, the turbine 4 and the bearing portion with radial bearing surface 5 'first connected to each other to the rotor 1 and this then clamped in finished assembled state, in particular in the lathe and post-processed there. With the post-processing in "a voltage" to achieve optimum concentricity of all surfaces of the individual components of the rotor 1, which reduces the imbalance and simplifies the assembly of the rotor 1 in the charging device. Alternatively, instead of clamping in a lathe also a centerless editing done, wherein the workpiece is not clamped between the headstock and tailstock, but out between grinding and regulating wheel and held from below by means of a rail. The possible surfaces of the rotor 1, which are post-processed in the inventive method, are in FIG. 1 denoted by the line 6. It is thus possible to rework the almost entire rotor 1 with the exception of a small area in the region of the centering holes 7 and thereby to optimize them in terms of rotational symmetry. However, it would also be conceivable to process only the outer radial bearing surfaces 5, 5 'of the rotor 1 in a voltage.

Die Bereiche um die Zentrierbohrungen 7 können in der Drehbank nicht bearbeitet werden, so dass diese Bereiche nach dem Ausspannen des Rotors 1 weg geschliffen oder weg erodiert werden. Die Vorderkanten der Verdichterradschaufeln und die Hinterkanten der Turbinenradschaufeln werden ebenfalls nicht in einer Spannung bearbeitet.The areas around the centering holes 7 can not be processed in the lathe, so that these areas are ground away after erasing the rotor 1 or eroded away. The leading edges of the compressor wheel blades and the trailing edges of the turbine blades are also not machined in tension.

Die Lagerabschnitte dienen dabei der Radiallagerung des Rotors 1 in einem Lagergehäuse der Ladeeinrichtung, wobei nach dem Bearbeiten des Rotors 1 in der Drehbank die axialen Stirnflächen 8, 8' eines Axialluftlagers 9 (vergleiche Figur 2) durch Laserstrukturierung bearbeitet werden. Selbstverständlich können dabei die einzelnen das Axialluftlager 9 bildende spiralförmig angeordnete Rillen 10 anderweitig hergestellt werden, beispielsweise mittels Ätzen oder Erodieren oder mittels spanabhebendem Verfahren.The bearing sections serve the radial bearing of the rotor 1 in a bearing housing of the charging device, wherein after machining the rotor 1 in the lathe, the axial end faces 8, 8 'of an axial bearing 9 (see FIG. 2 ) be processed by laser structuring. Of course, it is possible for the individual spirally arranged grooves 10 forming the axial air bearing 9 to be produced otherwise, for example by means of etching or erosion or by means of a metal-cutting process.

Mit dem erfindungsgemäßen Verfahren ist es somit möglich, die einzelnen Rotorteile, beispielsweise die Lagerabschnitte, das Verdichterrad 2, die Labyrinthdichtung 3 und das Turbinenrad 4 nicht mehr separat wuchten zu müssen, wodurch die Herstellungskosten deutlich reduziert werden können. Darüber hinaus können mit dem erfindungsgemäßen Verfahren alle wichtigen Oberflächen aus "einer Spannung" gefertigt werden, wodurch eine maximale Konzentrizität und eine maximale Rotationssymmetrie bei gleichzeitig minimalen Kosten erreicht werden können.With the method according to the invention, it is thus possible to no longer have to balance the individual rotor parts, for example the bearing sections, the compressor wheel 2, the labyrinth seal 3 and the turbine wheel 4, whereby the production costs can be significantly reduced. In addition, with the method according to the invention, all important surfaces can be manufactured from "one tension", whereby maximum concentricity and maximum rotational symmetry can be achieved with at the same time minimal costs.

Claims (9)

Verfahren zur Herstellung eines Rotors (1) einer Ladeeinrichtung, insbesondere eines Abgasturboladers, mit zumindest einem Verdichterrad (2) und einem Turbinenrad (4) wobei längsendseitig jeweils noch ein Lagerabschnitt mit einer Radiallagerfläche (5, 5') zum Lagern des Rotors (1) in einem Lagergehäuse vorgesehen ist,
dadurch gekennzeichnet, - dass zumindest die Radiallagerflächen (5, 5') mit radialem Übermaß gefertigt werden, - dass das Verdichterrad (2) und das Turbinenrad (4) und die Lagerabschnitte zum Rotor (1) zusammengebaut werden, - dass zumindest die Radiallagerflächen (5, 5') des fertig zusammengebauten Rotors (1) anschließend bearbeitet, insbesondere gedreht oder geschliffen wird, bis die Radiallagerflächen (5, 5') rotationssymmetrisch sind. Method for producing a rotor (1) of a charging device, in particular of an exhaust-gas turbocharger, with at least one compressor wheel (2) and a turbine wheel (4), wherein a bearing section with a radial bearing surface (5, 5 ') for supporting the rotor (1) is provided in a bearing housing,
characterized, - That at least the radial bearing surfaces (5, 5 ') are manufactured with radial oversize, - That the compressor wheel (2) and the turbine wheel (4) and the bearing sections to the rotor (1) are assembled, - That at least the radial bearing surfaces (5, 5 ') of the finished assembled rotor (1) subsequently processed, in particular rotated or ground until the radial bearing surfaces (5, 5') are rotationally symmetrical. Verfahren nach Anspruch 1,
dadurch gekennzeichnet, - dass das Turbinenrad (4) über eine Labyrinthdichtung (3) mit dem Verdichterrad (2) verbunden wird, - dass der aus Lagerabschnitten, Turbinenrad (4), Labyrinthdichtung (3) und Verdichterrad (2) fertig zusammengebaute Rotor (1) anschließend bearbeitet, insbesondere gedreht oder geschliffen wird, bis er rotationssymmetrisch ist. Method according to claim 1,
characterized, - That the turbine wheel (4) via a labyrinth seal (3) with the compressor wheel (2) is connected, - That from bearing sections, turbine wheel (4), labyrinth seal (3) and compressor wheel (2) finished assembled rotor (1) then machined, in particular rotated or ground until it is rotationally symmetrical. Verfahren nach Anspruch 1 oder 2,
dadurch gekennzeichnet,
dass zumindest zwei Bauteile des Rotors (1), insbesondere das Verdichterrad (2), die Labyrinthdichtung (3) und/oder das Turbinenrad (4) miteinander verschweißt, verlötet oder verklebt oder verschraubt werden.Method according to claim 1 or 2,
characterized,
in that at least two components of the rotor (1), in particular the compressor wheel (2), the labyrinth seal (3) and / or the turbine wheel (4), are welded, soldered or glued or screwed together. Verfahren nach einem der Ansprüche 1 bis 3,
dadurch gekennzeichnet, - dass axiale Stirnflächen (8,8') der Lagerabschnitte mit radialem Übermaß mittels gefertigt werden, - dass das Verdichterrad (2) und das Turbinenrad (4) und die Lagerabschnitte zum Rotor (1) zusammengebaut werden, - dass zumindest die Radiallagerflächen (5, 5') und Stirnflächen (8, 8') des fertig zusammengebauten Rotors (1) anschließend bearbeitet, insbesondere gedreht oder geschliffen werden, bis die Radiallagerflächen (5, 5') rotationssymmetrisch und die Stirnflächen (8, 8') senkrecht zu den Radiallagerflächen (5,5') sind. Method according to one of claims 1 to 3,
characterized, that axial end faces (8, 8 ') of the bearing sections are manufactured with radial oversize, - That the compressor wheel (2) and the turbine wheel (4) and the bearing sections to the rotor (1) are assembled, - That at least the radial bearing surfaces (5, 5 ') and end faces (8, 8') of the finished assembled rotor (1) subsequently machined, in particular rotated or ground until the radial bearing surfaces (5, 5 ') rotationally symmetrical and the end faces (8 , 8 ') are perpendicular to the radial bearing surfaces (5,5'). Verfahren nach Anspruch 4,
dadurch gekennzeichnet,
dass in die axialen Stirnflächen (8,8') ein Axialluftlager (9) geätzt oder erodiert oder durch Laserstrukturierung bearbeitet wird.Method according to claim 4,
characterized,
in that an axial air bearing (9) is etched or eroded into the axial end faces (8, 8 ') or machined by laser structuring. Verfahren nach Anspruch 5,
dadurch gekennzeichnet,
dass der Rotor (1) nach dem Einbringen des Axialluftlagers (9) gewuchtet wird.Method according to claim 5,
characterized,
that the rotor (1) after the introduction of the axial air bearing (9) is balanced. Verfahren nach einem der Ansprüche 1 bis 6,
dadurch gekennzeichnet,
zumindest die Radiallagerflächen (5, 5') und Stirnflächen (8, 8') des fertig gebauten Rotors (1) in einer Drehbank oder spitzenlos bearbeitet, insbesondere gedreht oder geschliffen werden, bis die Radiallagerflächen (5, 5') rotationssymmetrisch und die Stirnflächen (8, 8') senkrecht zu den Radiallagerflächen (5,5') sind.Method according to one of claims 1 to 6,
characterized
at least the radial bearing surfaces (5, 5 ') and end faces (8, 8') of the finished rotor (1) processed in a lathe or centerless, in particular rotated or ground, until the radial bearing surfaces (5, 5 ') rotationally symmetrical and the end faces (8, 8 ') are perpendicular to the radial bearing surfaces (5,5'). Rotor (1), hergestellt nach dem Verfahren nach einem der Ansprüche 1 bis 7.Rotor (1), produced by the method according to one of claims 1 to 7. Ladeeinrichtung, insbesondere ein Abgasturbolader, mit einem Rotor (1) nach Anspruch 8.Charging device, in particular an exhaust gas turbocharger, with a rotor (1) according to claim 8.
EP15175069.2A 2014-08-05 2015-07-02 Method for producing a rotor of a charging apparatus Not-in-force EP2982470B1 (en)

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EP2982470B1 (en) 2017-04-12
US9970309B2 (en) 2018-05-15
DE102014215441A1 (en) 2016-02-11
CN105317464B (en) 2018-02-23
US20160040545A1 (en) 2016-02-11

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